U.S. patent application number 14/741312 was filed with the patent office on 2015-10-08 for end effector.
This patent application is currently assigned to PROPACK PROCESSING AND PACKAGING SYSTEMS, INC.. The applicant listed for this patent is PROPACK PROCESSING AND PACKAGING SYSTEMS, INC.. Invention is credited to Kevin George Crosby.
Application Number | 20150283708 14/741312 |
Document ID | / |
Family ID | 53043151 |
Filed Date | 2015-10-08 |
United States Patent
Application |
20150283708 |
Kind Code |
A1 |
Crosby; Kevin George |
October 8, 2015 |
END EFFECTOR
Abstract
An end effector for the packaging industry comprises has a
frame, a bridge on top of the frame, a rack and pinion assembly,
actuation rods, carrier assemblies, and vacuum ports. The rack and
pinion assembly is configured to be operatively connected to a
robot's rotatable shaft, and to the actuation rods. The actuation
rods are fixedly connected to one or more of the carrier
assemblies. As the robot's shaft rotates, the rack and pinion
assembly is actuated, which actuates the actuation rods, which
causes the carrier assemblies fixedly connected to the actuation
rods to move longitudinally along the frame. Each carrier assembly
includes a carrier block and at least one pick-up member. Each
carrier block has at least one arm with a grabber to cooperate with
an adjacent arm with grabbers of an adjacent carrier block(s) of
the same subgroup.
Inventors: |
Crosby; Kevin George;
(Beamsville, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
PROPACK PROCESSING AND PACKAGING SYSTEMS, INC. |
Beamsville |
|
CA |
|
|
Assignee: |
PROPACK PROCESSING AND PACKAGING
SYSTEMS, INC.
Beamsville
CA
|
Family ID: |
53043151 |
Appl. No.: |
14/741312 |
Filed: |
June 16, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14536653 |
Nov 9, 2014 |
9073222 |
|
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14741312 |
|
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61904418 |
Nov 14, 2013 |
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Current U.S.
Class: |
294/188 ;
294/81.6; 901/40 |
Current CPC
Class: |
B65B 35/38 20130101;
Y10S 901/40 20130101; B25J 15/0061 20130101; B25J 15/0616 20130101;
B65B 5/08 20130101; B65G 47/918 20130101 |
International
Class: |
B25J 15/06 20060101
B25J015/06 |
Claims
1-20. (canceled)
21. An end effector comprising: a frame; a plurality of carrier
assemblies slidingly engaged with the frame and configured for
longitudinal sliding movement along the frame, the plurality of
carrier assemblies comprising a first carrier assembly, and a
second carrier assembly; a first actuation device operably attached
to the first carrier assembly and configured to move the first
carrier assembly in a reciprocating motion; the first carrier
assembly comprising a first carrier block having a first arm
extending laterally therefrom towards the second carrier assembly,
the first arm having a first grabber; and the second carrier
assembly comprising a second carrier block having a second arm
extending laterally therefrom towards the first carrier assembly,
the second arm having a second grabber configured to engage the
first grabber.
22. The end effector of claim 21, further comprising a vacuum port
configured for connection to a vacuum source via a flexible
tube.
23. The end effector of claim 21, wherein the first actuation
device comprises a first actuation rod having a first portion
operably coupled to the first carrier assembly and a second portion
operably coupled to a driving mechanism configured to move the
first actuation rod in a reciprocating motion.
24. The end effector of claim 23, wherein the driving mechanism
comprises a rack and pinion assembly comprising a rack slidably
coupled to the frame and a pinion operably engaged with the rack
such that rotational movement of the pinion causes linear movement
of the rack and of a spindle assembly, the spindle assembly having
a first end operatively connected to the pinion assembly, and a
second end configured to operably couple to a rotating shaft of a
robot.
25. The end effector of claim 24, further comprising a connector
plate configured to connect the end effector to the robot.
26. The end effector of claim 24, further comprising a rack rail
fixedly mounted to the frame, and wherein the rack is slidingly
engaged with the rack rail.
27. The end effector of claim 26, further comprising a connector
plate configured to connect the end effector to the robot.
28. The end effector of claim 27, further comprising a vacuum port
configured for connection to a vacuum source via a flexible
tube.
29. The end effector of claim 21, wherein the first grabber
comprises a first hook depending from the first arm and the second
grabber comprises a second hook depending from the second arm, and
wherein the first hook and second hook are oppositely oriented such
that when the first carrier assembly is slidingly moved
longitudinally along the frame by the first actuation device a
sufficient distance away from the second carrier assembly, the
first hook couples to the second hook to cause the second carrier
assembly to move longitudinally along the frame with the first
carrier assembly.
30. The end effector of claim 21, wherein the first grabber extends
from the first arm toward the second grabber and the second grabber
extends from the second arm toward the first grabber such that when
the first carrier assembly is slidingly moved longitudinally along
the frame by the first actuation device a sufficient distance away
from the second carrier assembly, the first grabber couples to the
second grabber to cause the second carrier assembly to move
longitudinally along the frame with the first carrier assembly.
31. An end effector comprising: a frame; a plurality of carrier
assemblies slidingly engaged with the frame and configured for
longitudinal sliding movement along the frame, the plurality of
carrier assemblies comprising a first carrier assembly, a second
carrier assembly, a third carrier assembly and a fourth carrier
assembly; a first actuation device operably attached to the first
carrier assembly and configured to move the first carrier assembly
in a reciprocating motion; a second actuation device operably
attached to the fourth carrier assembly and configured to move the
fourth carrier assembly in a reciprocating motion; the first
carrier assembly comprising a first carrier block having a first
arm extending laterally therefrom towards the second carrier
assembly, the first arm having a first grabber; the second carrier
assembly comprising a second carrier block having a second arm
extending laterally therefrom towards the first carrier assembly,
the second arm having a second grabber configured to engage the
first grabber; the third carrier assembly comprising a third
carrier block having a third arm extending laterally therefrom
towards the fourth carrier assembly, the third arm having a third
grabber; and the fourth carrier assembly comprising a fourth
carrier block having a fourth arm extending laterally therefrom
towards the third carrier assembly, the fourth arm having a fourth
grabber configured to engage the third grabber.
32. The end effector of claim 31, further comprising a vacuum port
configured for connection to a vacuum source via a flexible
tube.
33. The end effector of claim 31, wherein: the first actuation
device comprises a first actuation rod having a first portion
operably coupled to the first carrier assembly and a second portion
operably coupled to a driving mechanism configured to move the
first actuation rod in a reciprocating motion; and the second
actuation device comprises a second actuation rod having a first
portion operably coupled to the fourth carrier assembly and a
second portion operably coupled to the driving mechanism configured
to move the second actuation rod in a reciprocating motion.
34. The end effector of claim 33, wherein: the driving mechanism
comprises 1) a rack and pinion assembly comprising a first rack
slidably coupled to the frame, a second rack slidably coupled to
the frame, and a pinion operably engaged with the first rack and
the second rack such that rotational movement of the pinion causes
linear movement of the first rack and the second rack, and 2) a
spindle assembly having a first end operatively connected to the
pinion assembly, and a second end configured to operably couple to
a rotating shaft of a robot.
35. The end effector of claim 34, further comprising a connector
plate configured to connect the end effector to the robot.
36. The end effector of claim 34, further comprising: a first rack
rail fixedly mounted to the frame, the first rack slidingly engaged
with the first rack rail; and a second rack rail fixedly mounted to
the frame, the second rack slidingly engaged with the second rack
rail.
37. The end effector of claim 36, further comprising a connector
plate configured to connect the end effector to the robot.
38. The end effector of claim 37, further comprising a vacuum port
configured for connection to a vacuum source via a flexible
tube.
39. The end effector of claim 31, wherein: the first grabber
comprises a first hook depending from the first arm and the second
grabber comprises a second hook depending from the second arm, and
wherein the first hook and second hook are oppositely oriented such
that when the first carrier assembly is slidingly moved
longitudinally along the frame by the first actuation device a
sufficient distance away from the second carrier assembly, the
first hook couples to the second hook to cause the second carrier
assembly to move longitudinally along the frame with the first
carrier assembly; and the fourth grabber comprises a fourth hook
depending from the fourth arm and the third grabber comprises a
third hook depending from the third arm, and wherein the fourth
hook and third hook are oppositely oriented such that when the
fourth carrier assembly is slidingly moved longitudinally along the
frame by the second actuation device a sufficient distance away
from the third carrier assembly, the fourth hook couples to the
third hook to cause the third carrier assembly to move
longitudinally along the frame with the fourth carrier
assembly.
40. The end effector of claim 31, wherein: the first grabber
extends from the first arm toward the second grabber and the second
grabber extends from the second arm toward the first grabber such
that when the first carrier assembly is slidingly moved
longitudinally along the frame by the first actuation device a
sufficient distance away from the second carrier assembly, the
first grabber couples to the second grabber to cause the second
carrier assembly to move longitudinally along the frame with the
first carrier assembly; and the fourth grabber extends from the
fourth arm toward the third grabber and the third grabber extends
from the third arm toward the fourth grabber such that when the
fourth carrier assembly is slidingly moved longitudinally along the
frame by the second actuation device a sufficient distance away
from the third carrier assembly, the fourth grabber couples to the
third grabber to cause the third carrier assembly to move
longitudinally along the frame with the fourth carrier assembly.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional
Application No. 61/904,418, filed on Nov. 14, 2013, in accordance
with 35 U.S.C. Section 119(e), and any other applicable laws. The
contents of the aforementioned application(s) are hereby
incorporated herein by reference in their entirety as if set forth
fully herein.
BACKGROUND
[0002] The field of the invention generally relates to end
effectors for picking and placing objects, and are typically used
with robotic arms for picking up items off a conveyor belt and
placing them in bulk packaging.
[0003] End effectors, also known as end-of-arm tools, in general
are well-known in the art. In the packaging industry, an end
effector is typically attached to the end of a robotic arm from a
robot such as a Delta Robot. The robot controls the robot arm,
which in turn controls movement of the end effector. The robot
further includes a rotatable shaft to actuate an actuation
mechanism of the end effector, to control movement of individual
carrier assemblies. This is done typically to retrieve (pick) items
(e.g., candy bars or other food items) from a first conveyor belt,
and deliver (place) them into containers such as boxes on a second
conveyor belt for retail distribution.
[0004] A typical end effector has carrier assemblies that each
include a carrier block either fixed to the frame of the end
effector, or slidingly engaged to the frame, with one or more
pick-up members (typically suction cups) attached thereto and
operatively connected to a vacuum source. The quantity and
arrangement of the pick-up members may vary depending on the
application. For example, an end effector designed to pick up two
rows of 8 items each at a first diverged pitch, then place them
into packaging in groups of 4 at a second pitch, is referred to
herein as a 4.times.4, 4 by 4, or 4-4, since each side of the end
effector would converge the items into 2 groups of 4 in preparation
for placing them into the packaging, resulting in groups on each
side of 4 and 4.
[0005] A first set of parameters associated with the items on the
first conveyor belt are determined, such as their shape,
dimensions, configuration, orientation, distance between each item,
and distance between each group of items, and the first conveyor
belt moves at a known speed. These parameters may be preset,
programmed, and/or adjusted as needed. Likewise, the packages that
receive the items are on a second conveyor belt, with a known
second set of parameters that may differ from the first set of
parameters. The end effectors are typically custom-designed to
accommodate the parameters for a specific application. In this
manner, the robot and end effector may be programmed and designed
to pick up items at a first pitch and place them into packaging at
a second pitch as required.
[0006] In order for the pick-up members to pick up items at a first
pitch, and place them into a package at a second pitch, the pick-up
members must be moveable. Various end effector designs are known
for doing so. For example, some earlier successful designs, such as
those manufactured by Demaurex, connect (via a connector) to the
robot arm, and also have a spindle operatively connected to a
rotatable shaft of the robot. The end of the shaft attached to the
end effector is attached to a rotary rack and pinion actuation
mechanism associated with the end effector, with arms extending out
from the pinion attached to carrier blocks on either side of the
end effector. As the robot rotates the shaft, the pinion thus
rotates, causing the arms to move accordingly, which in turn causes
the carrier blocks with the pick-up members to move longitudinally
along the body of the end effector. FIGS. 12-13 are selected pages
of a Demaurex manual from the year 2000, illustrating several views
of the Demaurex end effector with the connector, rack, and pinion
annotated. In the Demaurex device, the pick-up members are all
directly connected to the arms, and thus move in synch with the
arms.
[0007] Another known design uses a rotary cam and cam blocks
instead of a rack and pinion. See, e.g., U.S. Pat. No. 7,390,040
(Subotincic), the contents of which are incorporated herein by
reference. Subotincic describes having only certain pick up members
directly connected to the actuation mechanism. Other pick up
members are indirectly connected to the actuation mechanism, and
are moved by the directly-connected pick-up members by way of tie
links. The tie links are small plastic pieces often dangling (not
fixed) from the bottom of the end effector and move at high speeds.
Also, access to the rotary mechanism is difficult in the Subotincic
design, making installation, repair, and maintenance challenging at
times.
SUMMARY
[0008] In one embodiment, the present invention is directed to an
end effector comprising a frame, a bridge, a rack assembly, a
pinion assembly, and a spindle assembly (collectively, the rack
assembly, pinion assembly and spindle assembly referred to as a
rack and pinion assembly), actuation rods, carrier assemblies, and
vacuum ports. The rack and pinion assembly has a robot interface
configured to be operatively connected to a robot's rotatable
shaft, and an actuation interface operatively coupled to the
actuation rods. The actuation rods are fixedly connected to one or
more of the carrier assemblies. Thus, as the robot's shaft rotates
about its axis, the rack and pinion assembly is actuated, which in
turn actuates the actuation rods, which causes the carrier
assemblies fixedly connected to the actuation rods to move
longitudinally along the frame.
[0009] In one aspect of the present invention, less than all of the
carrier assemblies are directly connected to the actuation rods.
The carrier assemblies directly connected to the actuation rods are
referred to as "directly connected" carrier assemblies and the
carrier assemblies not directly connected to the actuation rods are
referred to as "non-connected" carrier assemblies or "indirectly
connected" carrier assemblies. Cooperating members on each of the
carrier assemblies are used to couple the non-connected carrier
assemblies to the directly connected carrier assemblies such that
the movement of the directly connected carrier assemblies causes
movement of the non-connected carrier assemblies. In one
embodiment, the cooperating members are arms having grabbers. Each
carrier assembly includes a carrier block and at least one pick-up
member. Each carrier block has one or more arms extending towards
an adjacent carrier assembly. Each arm has a grabber to cooperate
with the grabber of the adjacent carrier block of the same
subgroup, wherein during movement in the direction of divergence of
the carrier assemblies the adjacent grabbers move into contact with
each other and the grabbers engage such that first carrier assembly
of the adjacent carrier assemblies pulls the other carrier assembly
in the direction of movement of the first carrier assembly until at
their full travel they lock into position at full divergence.
During movement in the direction of convergence of the carrier
assemblies, the grabbers disengage and glide along the surface of
their adjacent arms and/or through slots in the openings of the
adjacent carrier blocks until full convergence is achieved. At full
convergence, the carrier blocks typically abut, either by side
walls or by detents or tabs, such that movement of a first carrier
assembly of the adjacent carrier assemblies pushes the other
carrier assembly in the. Thus as the carrier assemblies fixedly
connected to the actuation rods move longitudinally along the
frame, adjacent carrier members in the same subgroup are moved as
described herein.
[0010] In additional aspects of the present invention, the rack
assembly may comprise rack rails fixedly mounted to the bridge with
each rack rail having a rack slidingly engaged with the rack rail.
The end effector may also include a robot interface in the form of
a connector plate configured to be couple the end effector to a
robot. The end effector may also include one or more vacuum ports
for connecting the end effector to a vacuum source for applying a
vacuum to the pick-up members of each of the carrier
assemblies.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a bottom perspective view of an end effector with
the carrier assemblies in a diverged position, according to one
embodiment of the present invention;
[0012] FIG. 2 is a bottom perspective view of the end effector of
FIG. 1, with the carrier assemblies in a converged position,
according to one embodiment of the present invention;
[0013] FIG. 3 is a top perspective view of the right side of the
end effector of FIG. 1, with the carrier assemblies in a converged
position, according to one embodiment of the present invention;
[0014] FIG. 4 is a top perspective view of the right side of the
end effector of FIG. 1, with the carrier assemblies in a diverged
position, according to one embodiment of the present invention
[0015] FIG. 5 is bottom view of the end effector of FIG. 1,
according to one embodiment of the present invention;
[0016] FIG. 6 is an enlarged, partial bottom view of the end
effector of FIG. 1, with the carrier assemblies in a partially
diverged position according, to one embodiment of the present
invention;
[0017] FIG. 7 is an enlarged, partial, bottom perspective view of
the end effector of FIG. 1, with the carrier assemblies in a
diverged position, according to one embodiment of the present
invention;
[0018] FIG. 8 is an enlarged partial, bottom perspective view of
the end effector of FIG. 1, with the carrier assemblies in a
partially converged position, according to one embodiment of the
present invention;
[0019] FIG. 9 is an enlarged partial, exploded, side view of the
end effector of FIG. 1, according to one embodiment of the present
invention;
[0020] FIG. 10 is an enlarged partial, exploded, side perspective
view of the end effector of FIG. 1, according to one embodiment of
the present invention;
[0021] FIG. 11 is an enlarged, partial, perspective side view of
the end effector of FIG. 1 showing the pinion assembly removed,
according to one embodiment of the present invention;
according;
[0022] FIGS. 12A, 12B and 12C illustrate an alternative embodiment
of carrier assemblies, according to another embodiment of the
present invention.
[0023] FIG. 13 illustrates several views of a subassembly of a
prior art Demaraux end effector.
[0024] FIG. 14 illustrates several views of another subassembly of
a prior art Demaraux end effector.
DETAILED DESCRIPTION
[0025] The present invention comprises an end effector comprising a
rack and pinion assembly having a robot interface configured to be
operatively connected to the robot's rotatable shaft at one end,
and an actuation interface configured to operatively connect to
actuation rods at the other end. The actuation rods are fixedly
connected to one or more carrier assemblies, such that the carrier
assemblies move in synch therewith. Other carrier assemblies may be
indirectly connected to an actuation rod, (i.e., they move not in
synch therewith), or fixed to a frame of the end effector. The
carrier assemblies each have at least one pick-up member configured
to pick-up an object, such as by using a controllable vacuum to
grasp an object, and then place the object, such as by releasing
the vacuum. The carrier assemblies are movable relative to the
overall end effector so that the carrier assemblies can be arranged
to in a first pattern (e.g. pitch or spacing) pick-up a plurality
of objects in the first pattern (e.g. pitch or spacing), and then
be moved to a second pattern (e.g. pitch or spacing) to place the
plurality of objects in the second pattern. Typically, the entire
end effector is also moved by a robot between a first location to
pick-up the objects and a second location different from the first
location to place the plurality of objects.
[0026] Referring to FIGS. 1-8, one embodiment of an end effector 10
according to the present invention is shown. The end effector 10
comprises a frame 12 to which a plurality of carrier members 14 are
slidingly (or otherwise movably) engaged to frame 12. The frame 12
may be constructed from a lightweight aluminum or other metal, or
other suitable material such as carbon fiber composites,
fiberglass, etc. In this described embodiment, the frame 12 is an
elongate, hollow tube having a substantially rectangular
cross-section. The hollow tube structure forms an air flow
passageway through the frame which allows the frame 12 to also
function as a manifold and conduit for the vacuum air flow between
a vacuum source, and the various vacuum ports and other vacuum
manifolds on the end effector 10, as described below. The external
surface of the frame 12 has a frame groove 11 to slidingly engage a
frame guide 66 of each of the carrier assemblies 14 to slidingly
couple the carrier assemblies 14 to the frame 12.
[0027] A bridge assembly 16 is attached to a top surface of the
frame 12. The bridge assembly may be a single, integral structure,
or as is shown in this exemplary embodiment, an assembly of
multiple pieces connected together. The bridge assembly 16 may be
constructed of any of the same materials as the frame 12, as
described above. As better shown in FIGS. 3-4, the bridge assembly
16 is comprised of a flat top plate 18, and two side supports 20
connected to the top piece at opposing ends of the top piece 18.
The side supports 20 each include a vertical support 22 and a
lateral support 24 to provide structural integrity. The top plate
18 and side supports 20 may have holes in their surfaces to reduce
weight while not compromising structural integrity.
[0028] The bridge assembly 16 is attached to the frame at multiple
stress points using any suitable fastening device, such as screws,
rivets, hex-bolts, bolts, welding, or other suitable means, thereby
providing vertical support and lateral support to the connection
between a connector plate 26 of a robot (now shown) and the end
effector 10. The connector plate 26 may be bolted to machined screw
holes in the top plate 18 of the bridge assembly 16 using the bolts
28. This provides the structural strength required during
high-speed operation of the end effector 10.
[0029] The bridge assembly 16 has an opening 32 (see FIG. 10) in
the top plate 18 to allow a spindle assembly 52 of a rack and
pinion assembly 50 to pass vertically through the opening 32. The
opening 32 may be substantially circular, or have at least a
semi-circular portion. As described in more detail below, the
spindle assembly 52 couples a pinion assembly 54 to the robot's
rotatable shaft thereby transferring rotation of the robot's
rotatable shaft to rotate the pinion assembly 54. The bridge
assembly 16 also has an access opening 30 in the form of a frontal
cutout 30 in the top plate 18 configured to allow the spindle
assembly 52 to pass horizontally through the access opening 30,
typically while still attached to the pinion assembly 54. The
access opening 30 allows easy access for installation, repair and
maintenance of the rack and pinion assembly 50 without having to
further disassemble the end effector 10. The access opening 30 is
wide enough to allow the spindle assembly 52 (which is typically
cylindrical) to pass through the access opening, and still provide
some leeway for manual installation and removal of the spindle
assembly 52.
[0030] The bridge assembly 16 has a plurality of rail supports 36
(also referred to as rail braces) for securing rack rails 38 in
place, one on the front side and one on the back side of the bridge
assembly 16. The rail supports 36 may be formed as part of the side
supports 20, as shown in the exemplary embodiment, or they may be
separate parts fastened to the bridge assembly 16. The rack rails
38 may be attached to the rail supports 36 using any suitable
fastening means, such as screws, bolts, rivets, press-fitting,
welding, etc.
[0031] The bridge assembly 16 houses the pinion assembly 54. The
access opening 30 and the height of the top plate 18 above the
frame 12 are configured to provide sufficient space to allow the
pinion assembly 54 and spindle assembly 52 to be installed and
removed through this space without further disassembly of the end
effector or separating the pinion assembly 54 from the spindle
assembly 52.
[0032] The end effector 10 may also include various vacuum ports
located at strategic positions on the frame 12 to connect an air
vacuum source to the end effector 10 and to connect each of the
carrier assemblies 14 to the vacuum air flow. A pair of input
vacuum ports 40 are mounted on a top surface of the frame 12, one
towards each end of the elongate frame 12. The input vacuum ports
40 are mounted on the frame 12 over an opening into the frame 12
such that input vacuum ports 40 are in fluid communication with the
passageway in the frame 12. The input vacuum ports 40 are
configured to be connected to a vacuum source, such as vacuum
source tubing connected to a vacuum source, for providing a vacuum
air flow to the end effector 10. A plurality of distribution vacuum
ports 42 are mounted at spaced locations on a side surface of the
frame 12, such as a group of three distributions vacuum ports 42 at
each end of the frame 12. The groups of distribution vacuum ports
42 may be integrally formed into a distribution vacuum manifold
with ports 43, as shown in the exemplary embodiment, or they may be
separate structures. Each distribution vacuum port 42 is configured
to be connected via tubing (not shown) to a carrier vacuum port 44
on the carrier assemblies 14. Accordingly, an overall vacuum air
flow path through the end effector 10 is formed, commencing at the
pick-up members 15, into the carrier blocks 17 and out of the
carrier vacuum port 44, then through the tubing to the distribution
vacuum ports 42/43, then into and through the passageway in the
frame 12, then through the input vacuum ports 40, and finally
through the source tubing to the vacuum source. The vacuum ports 40
and 42 may be formed of any suitable material, such as polymers,
nylon, plastic, composites, etc. The vacuum ports 40 and 42 may be
of varying sizes, configurations, interfaces, and orientations, and
they may have multiple connections connected through a single part
and/or manifold. For instance, the input vacuum ports 40 may be 3/4
inch ports, and the distribution ports 42 may have multiple (such
as three) 1/4 inch ports. The carrier vacuum ports 44 are
preferably the same size as the distribution ports 42 (in this
example, 1/4 inch ports) so that the same size tubing can connect
between them.
[0033] Turning to FIGS. 9-11, the rack and pinion assembly 50
includes a pinion assembly 54 and a mating rack assembly. Referring
also to FIGS. 1-5, the rack assembly includes the left side rack
assembly 34a and the right side rack assembly 34b. Each rack
assembly 34 includes a rack rail 38 and a corresponding rack 35
slidingly coupled to the rack rail 38. Each rack rail 38 is fixedly
attached to the corresponding rail supports 36 of the bridge
assembly 16. Each rack 35 has an elongated portion with vertically
aligned teeth along its inside surface (surface facing the pinion
56) and a substantially smooth outside surface (surface facing and
engaging the rack rail 38). The outside surface of each rack 35 is
slidingly coupled to its corresponding rack rail 38, using any
suitable means. For example, nylon or other lightweight spacer may
be extruded and attached to the outside surface of the rack 35, to
slide within a mating extruded or machined slot in the inside
surface (the surface facing the rack 35) of rack rail 38. The
spacers may be attached to the racks 35 by any suitable means, such
as screws, bolts, rivets, glue, etc.
[0034] Each rack 35 has at least one rack brace 46 extending
downward from the bottom of the rack 35 and having a mounting
sleeve fixedly attaching the rack brace 46 to a corresponding
actuation rod 48, with one actuation rod 48 for each rack 35. The
actuation rod 48 fits into the mounting sleeve and a set screw is
used to fix the mounting sleeve in place on the actuation rod 48.
The rack brace 46 may be integrally molded as part of the rack 35,
or it may be a separate part attached to the rack 35, such as by a
press fit, bonding, fasteners, or other suitable means of
attachment to the rack 35.
[0035] The rack rails 38 may be constructed of aluminum or other
lightweight metal, or other suitable material. Each rack rail 38 is
secured in place by attachment to its corresponding rail support(s)
36 on the bridge assembly 16. The rack rails 38 may be
alternatively, or additionally, secured to the frame 12.
[0036] Referring again to FIGS. 9-11, the pinion assembly 54
includes a pinion 56, a pinion cover 58, and a spindle assembly 52.
The pinion 56 is a substantially circular toothed gear, with teeth
arranged vertically to mate with the teeth on the racks 35. The
pinion 56 may be made of any suitable material, preferably the same
as that used for the racks 35. The teeth on the pinion 56 may be
colored at various arcs. For example, first and second colors may
be used to color the teeth (and/or upper surface of the pinion)
every other x degrees (where x is 20, 25, 30, 35, 40, 45, 50, 55,
60, 65, 70, 75, 80, 85, 90, etc.), or each sector may have a unique
color. This may be helpful during maintenance to allow a technician
to rotate and reposition the pinion a certain amount so as to allow
previously-unengaged sectors of teeth to be positioned in a manner
to engage the racks 35 during operation, and likewise the previous
sectors of teeth that engaged the racks 35 during operation will be
rotated to non-engaging positions. This provides for more uniform
wear of the pinion 56, and a longer operating life.
[0037] The pinion 56 is positioned to be rotatably engaged between
the left side rack 35 (on the left rack assembly 34a) and the right
side rack 35 (on the right rack assembly 34b) during operation,
with teeth rotatably mating with the teeth of the racks 35. The
racks 35 and pinion 56 may be made of material similar to the
vacuum ports 40 and 42.
[0038] The pinion 56 may have a protective pinion cover 58, as seen
in FIGS. 9 and 11, which assists in keeping the pinion 56 engaged
with the racks 35 during operation. The pinion cover 56 may have
top surface cutouts sufficient for venting of heat and minimizing
weight, without compromising functionality, and frontal cutouts to
allow visual inspection of the pinion 56 during operation of the
end effector 10. The pinion cover 58 may be made of a material
similar to that used for the vacuum ports 40 and 42, the carrier
blocks 17, the racks 35, and/or the pinion 56.
[0039] The rack and pinion assembly 50 functions differently than
that of the Demaurex design shown in FIGS. 13 and 14, because some
of the carrier assemblies 14 in the present design are not directly
connected to the actuation rods 48, but instead are either fixed
(e.g., bolted or riveted to the frame) or moved by grabbers 21 of
adjacent carrier assemblies 14, as described in more detail
below.
[0040] The spindle assembly 52 has a housing and a rotatable shaft
configured to rotate within the housing. The rotating shaft has a
bottom end operatively connected to the pinion 56. The top end of
the rotatable shaft can be operatively connected to a mating
rotatable shaft of the robot. The top end of the housing is
configured to fixedly connect to the connector plate 26, for
example, by threaded mating portions. The spindle assembly 52 may
be custom-machined or altered from the off-the-shelf spindle
typically accompanying the robot, to accommodate specific
applications. Although the spindle assembly 52 is considered part
of the pinion assembly 54 as described herein for convenience, it
may also be considered a separate component.
[0041] Thus, the rack and pinion assembly 50 allows a rotational
force applied to the rack and pinion assembly 50 through the shaft
of the spindle assembly 52 to be translated into linear
longitudinal motion of the racks 35 and attached actuation rods 48.
Each of the actuation rods 48 is fixedly connected to one or more
directly-connected carrier assemblies 14 to directly move the
directly connected carrier assemblies 14 when the actuation rods 48
are actuated by the rack and pinion assembly 54. The
directly-connected carrier assemblies are connected to a
corresponding actuation rod 48 using a carrier mounting sleeve 60
which fixedly attaches to the actuation rod, similar to the
mounting sleeve of the rack brace 46. A set screw may be used to
fix the mounting sleeve 60 in place on the actuation rod 48.
Accordingly, the actuation rod 48 on the left side of the end
effector 10 is directly connected to, and actuates,
directly-connected carrier assemblies 14a and 14e (see FIG. 4). The
actuation rod on the right side of end effector 10 is directly
connected to, and actuates, directly-connected carrier assembles
14d and 14h which are directly connected to the is connected by a
rack brace to the rack on its side of the end effector, to cause
movement of the rod when the rack is actuated. Thus, when the robot
shaft rotates the shaft of the spindle assembly 52 which rotates
the pinion 56; the rotation of the pinion 56 actuates the racks 35
causing linear translation motion of the racks 35 in opposite
directions (i.e. the left side rack moves in the opposite direction
of the right side rack), which in turn causes linear motion of the
actuation rods 48 (also in opposite directions from each other),
which causes the directly connected carrier assemblies 14a, 14e,
14d and 14h to move in synch therewith (with carrier assemblies 14a
and 14e moving in a first direction and carrier assemblies 14d and
14h moving in the opposite direction). The actuation rods 48 may be
made of lightweight metal or other suitable material, similar to
the material used for the frame 12 and bridge 16.
[0042] Referring to FIGS. 6, 7 and 8 (and also FIGS. 1-4), each
carrier assembly 14 includes a carrier block 17 and at least one
pick-up member 15 attached to a pick-up housing 64 on the bottom of
the carrier block 17. In the exemplary embodiment, each carrier
assembly 14 includes two pick-up members 15, one for the right side
of the end effector 10 and one for the left side of the end
effector 10. The pick-up housing 64 includes an aperture for
receiving a flanged portion of each of the pick-up members 15 to
securely, and removably, attach the pick-up members 15 to the
carrier block 17. Each carrier block 17 has a carrier vacuum port
44 disposed at a top end of the carrier block 17. Each carrier
block 17 has an carrier block passageway providing an airflow path
from each of the pick-up members 15 to the carrier vacuum port
44.
[0043] Each of the carrier blocks 17 also has at least one arm 19
having a grabber 21 (or catch) extending longitudinally toward the
adjacent carrier block(s) 17. The carrier assemblies 14 of the end
effector 10 are configured in subgroups which are coupled together
by the arms 19 to be moved in cooperation with each other by the
actuation of the actuation rods 48. For example, in the exemplary
end effector 10, carrier assemblies 14a, 14b, 14c and 14 d are
configured in a left subgroup (left per the orientation of FIG. 5)
and carrier assemblies 14e, 14f, 14g and 14h are configured in a
right subgroup (again, right per the orientation of FIG. 5). The
end positioned carrier assemblies 14 (including 14a, 14d, 14e and
14h) of a subgroup have carrier blocks 17 each having a single arm
19 extending either right or left toward the adjacent carrier block
17. For instance, carrier block 17 of carrier assembly 14a is on
the left end of the left subgroup, and it has a single right arm 19
to cooperate with a left arm 19 extending from the adjacent carrier
block 17 of carrier assembly 14b. The internal carrier assemblies
14 have an adjacent carrier assembly 14 on both the left side and
right side (e.g. 14b, 14c, 14f and 14g). Each of the carrier blocks
17 of the internal carrier assemblies has a left arm 19 and a right
arm 19 with grabbers to cooperate with the arms 19 of adjacent
carrier blocks 17 of the same subgroup on each side. In other
words, each carrier block 17 (other than those on the end of a
pick-and-place subgroup) includes a right arm extending laterally
therefrom towards its adjacent carrier block 17 to the right, and a
left arm 19 extending laterally therefrom towards its adjacent
carrier block 17 to the left, except those carrier blocks 17 on the
end of a sub-group have only one arm 19, extending towards their
only adjacent carrier block 17. Each arm 19 may be a single
extending piece as seen in FIGS. 1-11, two extending pieces as seen
in FIGS. 12A-12C, or multiple extending pieces (not shown). The
arms 19 and grabbers 21 are configured such that when a
directly-connected carrier assembly 14 and its arm 19 with grabber
21 moves laterally away from a cooperating arm 19 with grabber 21
of an adjacent cooperating carrier assembly 14 (which is a
non-connected carrier assembly as configured on end effector 10) in
the same subgroup, the moving arm 19 with grabber slides along the
cooperating arm with grabber 21 until the moving grabber 21 bears
against the cooperating grabber 21, and then the moving arm 19 with
grabber 21 pulls the cooperating arm with grabber 21 (and its
corresponding carrier assembly 14) in the direction of the moving
arm 19 with grabber 21. This describes the actuation when the
carrier assemblies 14 are being actuated in a diverging motion from
a converged position (see FIGS. 2, 3, 5, 6 and 8) to a diverged
position (see FIGS. 1, 4, and 7). When the directly-connected
carrier assembly 14 is moved in the opposite direction (i.e. from
the diverged position shown in FIGS. 1, 4 and 7 to the converged
position shown in FIGS. 2, 3, 5, 6 and 8), the moving arm 19 with
grabber 21 of the directly-connected carrier assembly 14 slides
along the cooperating arm 19 with grabber 21 of the non-connected
carrier assembly 14. As the moving arm 19 with grabber 21 and the
cooperating arm 19 with grabber approach the respective adjacent
carrier blocks 17, the moving arm 19 with grabber 21 advances into
the slot 62 of the cooperating carrier block 17 and the cooperating
arm 19 with grabber 21 advances into the slot 62 of the moving
carrier block 17 until the moving carrier block 17 contacts the
cooperating carrier block. This position of the carrier assemblies
is shown in FIGS. 5 and 6, and may be considered the converged
position, or alternatively, a partially converged position,
depending on the desired pitch in the converged position. Continued
movement of the moving carrier block 17 pushes the cooperating
carrier block 17 to a further converged position, until the
cooperating carrier block 17 contacts the adjacent carrier block 17
on side opposite the moving carrier block 17, in which case, a
fully converged position of the carrier assemblies 14 is
attained.
[0044] The carrier blocks 17 may be constructed of material same or
similar to the racks 35 and pinion 56. Each carrier block 17 may be
molded as a single-piece, including the body, arms 17, grabbers 19,
and pick-up-member housing 64. Each carrier block 17 hosts one or
more pick-up members 15 (e.g., suction cups). The carrier blocks 17
are slidingly engaged with the frame 12 and configured for
longitudinal sliding movement along the frame 12. However, in some
embodiments, some carrier assemblies 14 may be fixed to the frame
12 for specific applications such that those fixed carrier
assemblies 14 do not move relative to the frame 12. Each arm 19 has
a grabber 21 configured to hook onto the grabber 21 of an arm from
its adjacent carrier block 17. The grabbers 21 may be in the form
of oppositely oriented fingers at the end of the arms 19, as seen
in the figures, for instance FIGS. 7 and 8. For example, the
grabber 21 on the arm 21 of one carrier block 17 may be pointed
vertically upward, while the grabber 21 on the arm 19 of an
adjacent carrier block 17 may be pointed vertically downward, as
seen in FIGS. 7 and 8.
[0045] FIGS. 7 and 8 show a side view of the end effector 10 and
the carrier assemblies 14. The carrier vacuum ports 44 on each of
the carrier blocks 17 can be seen. The carrier blocks 17 each have
a frame guide 66 which is slidingly received in the frame groove 11
to slidingly couple the carrier assemblies 14 to the frame 12. The
carrier blocks 17 each have a carrier slot 62 above the pick-up
member housing 64 just below the frame guide 66. The carrier slot
62 is configured to receive the arm(s) 19 of adjacent carrier
blocks 17 during convergence. The arms 19 of the internal carrier
blocks 17 are offset such that the right arm and left arm of the
carrier block offset, i.e., one extends from the front of the slot
and one extends from the back of the slot. ("Front" and "back" are
used as relative terms relative to the "right" and "left" terms
used to describe the direction of movement of the carrier blocks
longitudinally along the frame, corresponding to the "right" and
"left" arms of the carrier blocks.) The offset allows two arms 19
to be received in the carrier slot 62 at the front--one from the
carrier block 17 itself, and one from an adjacent carrier block
17--and two arms 19 to be received in the slot at the back--one
from the carrier block 17 itself, and one from an adjacent carrier
block 17, during convergence. Similarly, arms 19 on one carrier
block 17 extend outward (left and/or right) from the roof or upper
edge of the carrier slot 62, whereas the arms 19 of an adjacent
carrier block 17 in the same subgroup extend outward from the floor
or bottom of the carrier slot 62. This further allows the
cooperating arms 19 to glide or slide over/under each other during
convergence and divergence, as seen in FIGS. 7 and 8.
[0046] The carrier assemblies 14 are positioned for pick and place
based on programming of the robot according to the position of the
pick and place objects in the "pick" position and the "place"
position. Typically, the "pick position" has the objects in a
uniform array, such as in the present example, two rows of objects
with each row spaced at the diverged spacing of the carrier
assemblies 14 (see FIGS. 1, 4 and 7). The "place" phase of the
pick-and-place operation requires the carrier assemblies 14 (with
items secured to the pick-up members) to be positioned into
subgroups, typically at a pitch smaller than (or otherwise
different from) that at which the pick-up members "picked" the
items. Thus, the "place position" may have two subgroups of 4 on
each side of the end effector 10, in which the rows are spaced at
the converged spacing of the carrier assemblies 14 (see FIGS. 2, 3,
5, 6 and 8). For example, if the items are to be placed in 2 groups
of 4, the carrier assemblies 14 will be positioned such that each
side of the end effector 10 (right and left) has 2 subgroups of 4
pick-up members each (referred to herein as 4.times.4, 4 by 4, or
4-4).
[0047] FIGS. 12A, 12B and 12C show an alternative configuration for
carrier blocks 17a using arms 19a instead of the arms 19 described
above. The arms 19a include multiple extension arms and grabbers 21
instead of the single arm 19 and grabber 21, of the carrier blocks
17 described above. Otherwise, the carrier blocks 17 are the same
or substantially similar to the carrier blocks 17, the description
above applies equally to the carrier blocks 17, where applicable.
FIG. 12A shows the carrier assemblies 14 as separate parts. FIG.
12B shows the carrier assemblies 14 in a diverged position with the
grabbers 21 in an engaged position. FIG. 12B shows the carrier
assemblies 14 in a partially converged position with the grabbers
21 disengaged and the arms 19a extending into the carrier slots 62
of the adjacent carrier blocks 17.
[0048] The operation of the end effector 10 will now be described
with reference to the figures. It is understood that the end
effector 10 is to be attached to a robot by attaching an interface
member of the robot to the connector plate 26, and connecting the
robot's rotatable shaft to the top end (robot shaft interface) of
the spindle shaft of the spindle assembly 52 of the rack and pinion
assembly 50. A vacuum source is also connected to the input vacuum
ports 40 using suitable tubing. In addition, tubes (not shown) are
connected between the distribution vacuum ports 42 and each of the
carrier vacuum ports 44 of the carrier assemblies 14. The robot is
activated and controls the movement of the entire end effector 10,
as well as controlling the position of the carrier assemblies 14 by
controlling the position of the spindle shaft via the position of
the robot's rotatable shaft).
[0049] Starting with the carrier assemblies 14 in the diverged
position as shown in FIG. 1, the robot positions the end effector
10 over the objects to be picked up with each of the pick-up
members 15 above and/or against the objects to be picked. The robot
activates the vacuum source (such as be opening a valve) which
creates a vacuum at each of the pick-up members 15 via vacuum air
flow through the pathway as described above. The vacuum at each of
the pickup members 15 causes the objects to be picked up by the
pick-up members, and then the robot moves the end effector 10 to a
place location where the picked up objects will be placed. While
the end effector 10 is being moved and/or when it reaches the place
location, the robot actuates the end effector 10 to move the
carrier assemblies 14 to a converged position for placing the
objects at the desired pitch.
[0050] Referring to FIG. 1, the robot rotates the robot's rotatable
shaft in a clockwise direction (looking down on the end effector
10), thereby rotating the spindle shaft and the pinion 56 in a
clockwise direction. The clockwise rotation of the pinion gear
drives the racks 35 to move linearly, with the left rack 35 moving
backward (into the page according to the orientation of FIG. 1) and
the right rack 35 moving forward (out of the page according to the
orientation of FIG. 1). The movement of the racks 35 cause the
actuation rods 48 to move in the same direction as their
corresponding rack 35, which causes the directly connected carrier
assemblies 14a, 14e, 14d, and 14h to move in synch with their
corresponding actuation rods 48. In other words, carrier assemblies
14a and 14e move backward towards their corresponding adjacent
carrier assemblies 14b and 14f, respectively; and carrier
assemblies 14d and 14h move forward towards their corresponding
adjacent carrier assemblies 14c and 14g, respectively.
[0051] Depending on the desired pitch for the place position, the
robot's shaft may actuate the movement of the carrier assemblies 14
to the position where the directly connected carrier assemblies 14
just come into contact with the non-connected carrier assemblies 14
as shown in FIGS. 5, 6 and 8, or it may actuate them into a further
converged position in which the directly connected carrier
assemblies 14 bear against the non-connected carrier assemblies 14
and move them to a further converged position, as shown in FIGS. 2
and 3. When the end effector 10 is positioned in the place position
and the carrier assemblies 14 are actuated to the desired place
pitch, the robot de-actuates the vacuum (such as by closing a valve
to the vacuum source), causing the pick-up members 15 to release
the objects at the place position.
[0052] The robot then moves the end effector 10 to a position to
pick up more objects, and at the same time moves the carrier
assemblies 14 back to the diverged position. The robot rotates the
robot's rotatable shaft in a counter-clockwise direction (looking
down on the end effector 10), thereby rotating the spindle shaft
and the pinion 56 in a counter-clockwise direction. The c
counter-clockwise rotation of the pinion gear drives the racks 35
to move linearly, with the left rack 35 moving forward (out the
page according to the orientation of FIG. 1) and the right rack 35
moving backward (out of the page according to the orientation of
FIG. 1). The movement of the racks 35 cause the actuation rods 48
to move in the same direction as their corresponding rack 35, which
causes the directly connected carrier assemblies 14a, 14e, 14d, and
14h to move in synch with their corresponding actuation rods 48. In
other words, carrier assemblies 14a and 14e move forward away from
their corresponding adjacent carrier assemblies 14b and 14f,
respectively; and carrier assemblies 14d and 14h move backward away
their corresponding adjacent carrier assemblies 14c and 14g,
respectively, until the carrier assemblies are position in the
desired diverged position for the pick position. The process may
then be repeated as required.
[0053] The end effector 10 may also be configured to work in
connection with other actuation mechanisms and/or other carrier
movement mechanisms besides the rack and pinion actuation
mechanism, including rotary cams and cam blocks and/or tie links,
as described, e.g., in Subotincic, which is incorporated by
reference above.
[0054] Although particular embodiments have been shown and
described, it is to be understood that the above description is not
intended to limit the scope of these embodiments. While embodiments
and variations of the many aspects of the invention have been
disclosed and described herein, such disclosure is provided for
purposes of explanation and illustration only. Thus, various
changes and modifications may be made without departing from the
scope of the claims. For example, not all of the components
described in the embodiments are necessary, and the invention may
include any suitable combinations of the described components, and
the general shapes and relative sizes of the components of the
invention may be modified. Accordingly, embodiments are intended to
exemplify alternatives, modifications, and equivalents that may
fall within the scope of the claims. The invention, therefore,
should not be limited, except to the following claims, and their
equivalents.
* * * * *